Minimizing Distortion in Fusion Welding

Running head: ASSIGNMENT 1
ASSIGNMENT 1
Name of the Student
Name of the University
Author Note

ASSIGNMENT 11
Question 1:
1.1
In the GTAW root the welding process which is also known as the tungsten inert gas (TIG)
welding different types of non-consumable tungsten electrodes like the E7018 electrodes with
MMAW (Manual Metal Arc Welding) filter are used for producing the weld. The welding
process is common for welding the thin stainless steels and the metals like the Al, Mg and Cu
alloys those with no iron components (Feng et al. 2016). With the E7018 electrodes if the
ampere of current goes over the limit then melted tungsten can be included in weld which is
known as tungsten splitting. This tungsten inclusion reduces the quality of the weld in a
greater way and if included in a high percentage then it can cause rapid failure of weld. Thus
the repair weld can fail within 2 weeks if the GTAW root welding is performed with
excessive voltage or current supply. Now, rapid failure can also occur if the welding time in
GTAW welding is kept too less for welding a large number of long tubular carbon steel pipes
within few hours. As, the heating and cooling cycle times will be lesser than the normal in
this particular case. Also, if the length of the E7018 electrodes is very small then the number
of passes for doing the same amount of weld to individual carbon steel pipes will be more
and thus this introduces extra amount of the shrinkage and distortion. Hence, through this the
additional amount of distortion will lessen the strength and durability of the carbon pipes and
number of repairs will be increased.
1.2
Gas metal arc welding is a better welding process than the GTAW root welding as in this
case the required heat input to weld the carbon steel pipes is low enough and thus the gas
metal will not be included in the weld. For this welding type, externally supplied shielding
gas is needed, and some of the most common used gases for this purpose are stainless steel,

ASSIGNMENT 12
carbon steel, magnesium, copper, nickel, aluminium, and silicon bronze (Májlinger, Kalácska
and Spena 2016). The technique of GMAW is simple and as most of the process is
automated, it usually takes few weeks for workers to master it. This type of welding can
extend the life of weld as the carbon steel pipes can be welded very quickly with minimum
distortion effect in weld. The GMAW welding is also faster than the other types of welding
and thus extensively applied to weld carbon steels. The costing of the inert gas which is used
in welding is also limited to a certain amount. This type of welding is also applicable for its
speed and thus used with robotic automation. The number of items required to performed
GMAW welding is also very less as the items are welding gun and wire feed unit, tool style,
power supply, electrode, gas shielding accessory. Thus the amount of labour-hours and the
expense required to weld in GMAW welding is very limited and thus can be afforded by any
medium to small industries and in the dragline excavators.
Question 2:
The fusion welding is a method in which the heat is used to join or fuse at least two or many
materials (typically metals) by heating the materials to their melting point. In the fusion
welding process sometimes it is not required to a filter material. In fusion welding process
there is no need for external pressure except for the case of resistance welding where
substantial pressure contact is needed for the in welding to obtain a very good join.
The distortion while welding is mostly experienced common problem in the industries which
occurs mainly for the wrapping of the base plate through the heat generated from the welding
arc. Distortion is problematic for a good amount of reasons, however, the most critical reason
is that distortion causes a poor type of weld which is somehow defective by its structure. The
distortion is primarily produced by the successive expansion and contraction of the weld
metal and the base metal adjacent to it at the time of ongoing heating and cooling cycle of the